Orion is just badass. Cool backstory and a brutal attitude.
Strange has a killer costume, too. His cloak makes him fly, the amulet has uses, hell, even the insignia on his shirt is a protective enchantment.
Nothing is there for show.
War Machine had a great suit.
Venom's suit was cool for it's time.
Can't go wrong with The Punisher's costume.
I sort of liked Wolverine's original costume, with the smaller ears, sometimes not there at all.
Silver Surfer, when drawn right, is unequaled.
Slade's suit has always been crap, I even admit it.
Namor's pants must have been made from the same material then Hulk's (Hell, Namor was the original unbreakable-pants guy). Are they cloth-thin adamantium? Extraterrestial material? Atlantean fabric? Anyway, they take blasts as hot as sun, miniature nuclear bombs, blasts from Silver Surfer and other crap, and they still not break. They even don't rip, unlike Hulks. Damn, I wan't pants like that to protect my family jewels.
Anyway, the best costume to me has always been the New X-Men era X-Men costumes. Practical and cool.